Measurement

3 components
of Process Control

Decision Controller
Action

Type of Controller

Regulatory and servo control

For process that the controlled variable deviates from set

point because of disturbance regulatory control

For process that the most important disturbance is the set

point itself servo control

Unit 1: Terminology
Terminology

TC

I/P

Heat exchanger

Manipulated variable
(saturated steam)

95C

Controlled
variable

Manipulated
variable

Sym: c, PV

Sym: m, CO, MV

The parameters
that
indicate
product quality or
the
operating
condition of the
process.
(L.M.
Gordon)

A process being
adjusted (controlled)
by a final control
element (such as
control valve,
damper, motor
speed).

controlled variable
(temperature of
sterilised saline)

(Flow, temperature
of saline solution)

80C

100C
30C
100 L/min

Load variable

TT

Uncontrolled variable
(Saturated steam)

Load variable

Set point

Sym:

Sym: r, SP, SV

All other
affecting
variable, other
than the one
being
manipulated.
(L.M. Gordon)

The desired
operating
condition.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Unit 1: Control strategies

Feedback control

TC

I/P
Heat exchanger

TT

Manipulated variable
(saturated steam)
Load variable
(Flow of saline solution)

80C

100C
30C
100 L/min

What is feedback control?

controlled variable
(temperature of
sterilised saline)

95C

A method of control that the action taken is

based on past result.

Manipulated variable
(Saturated steam)

Merit?
Simple design. Easy to tune (for linear, fast &
short deadtime processes: flow, level &
pressure).

Demerits?
Slow recovery for slow process such as
temperature control upon load disturbance or
change in setpoint. A process with long deadtime
may exhibit oscillatory process response with
long settling time.

The Process
Saline solution at 30C is sterilized by
heating the solution in a heat-exchanger
system to 80C. The temperature of the
sterilized saline solution is maintained by
regulating the control valve of steam input
to the heat-exchanger.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Unit 1: Control strategies

TSP

Cascade control

I/P

FC
FT

FSP

Heat exchanger

TC
TT

Manipulated variable
(saturated steam)
Load variable
(Flow of saline solution)

80C

100C
30C
100 L/min

What is cascade control?

controlled variable
(temperature of
sterilised saline)

95C

A method of control of which the inner loop

controller obtains its setpoint from an outer loop
controller.

Manipulated variable
(Saturated steam)

Characteristic of cacade control:

Merit?
Faster recovery time as compared to SISO
feedback control.

Demerits?
Controllability will be worst than SISO if both
controllers were not properly tuned.

Two transmitters, two controllers and one

control valve (2-level cascade).

Application: Transform from SISO to

cascade strategy if faster recovery time is
desired.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Unit 1: Control strategies

Feedforward control
Ws

Cp
Hs

I/P

FFC

W p T2 T1

Manipulated variable
(saturated steam)
Load variable
(Flow of saline solution)

30C
100 L/min

FTTT

What is feedforward control?

Heat exchanger

controlled variable
(temperature of
sterilised saline)

95C

A method of control based on process model:

mass and energy balances.

Merit?
Faster recovery than cascade or SISO.
Compensate for disturbances before they effect
the controlled variable.

80C

Manipulated variable
(Saturated steam)

Characteristic of feedforward
control:
Measurements of load variables online and
Utilization of computational blocks.

Demerits?
Cannot work if any of the sensors fail esp. load
variable.
Requires process model in order to design
feedforward system.
Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Unit 1: Control strategies

Feedforward/
Feedback control
C
Ws

Hs

I/P

W p T2 T1

+
+
FFC

TC
TT

Manipulated variable
(saturated steam)
Load variable
(Flow of saline solution)

30C
100 L/min

FT TT

What is feedforward/feedback control?

Heat exchanger

80C
controlled variable
(temperature of
sterilised saline)

95C

Feedback compensation added to feedforward

control

Merit?
Feedforward control compensates for major
disturbances, while feedback control compensates
for all other disturbances.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Manipulated variable
(Saturated steam)

Unit 1: Control strategies

Ratio control

FC

I/P

X
FT
Manipulated variable
(saturated steam)

Wild flow
(Flow of saline solution)

FT

Heat exchanger

30C
100 L/min

controlled variable
(temperature of
sterilised saline)

95C

What is ratio control?

80C

Keeps a flowrate in proportion to another

flowrate.

Merit?
Keep two flow in proportion.

Demerits?
Inherits PID characteristics

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Manipulated variable
(Saturated steam)

Ratio Control

Type of feedforward control

The objective is to maintain the ratio of two
variables at a specified value
One variable is manipulated to keep it as ratio of
another.
Implemented in two basic schemes.
multiplier

divider

 Required to blend 2 liquid streams, A and B in some

ratio
R=FB/FA

The flow of stream B must vary, as the flow rate of

stream A is varies
Multiplier : set the ratio
(Wild flow)

Measuring the flow in steam A

Multiplying it with the desired ratio
to obtain the required flow rate in
stream B (set point to the flow
controller of stream B)
FBset = R x FA

If the flow of stream A varies, the

set point of the controller of stream
B will vary.

Divider

Measuring both stream

Divide them in FY16 to obtain the
actual ratio flowing through the
system
R=FB/FA

The calculated ratio is the sent to

the controller which manipulated
the flow B to maintain set point.
The set point to this controller is
the required ratio.

BLOCK DIAGRAM
Feedback control

Y(s)

Feedback
controller

Process

Feedforward control
D
Y(s)
Feedforward
controller

Process

Cascade control
Y(s)

Primary
controller

Secondary
controller

Process II

Process I

 Question
- How to ensure that the level in the tank remains at or near the set
point? Propose the following control strategy:
- Feedback
- Feedforward
- Feedforward/Feedback